Inflatable packaging with apertures

ABSTRACT

An inflatable packaging element is disclosed herein. The inflatable packaging element includes a first film ply and second film ply overlayed on the first ply, and a seal pattern. The seal pattern has a plurality of seals sealing the first and second plies to each other to define an inflation chamber between the first and second plies. The inflation chamber is inflatable with and configured to contain a fluid. An aperture extends through at least one of the first or second ply, and the seal pattern separates opposite side of the aperture from the inflation chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority of U.S.Provisional Patent Application No. 62/077,815 entitled “InflatableProduce Packaging,” and No. 62/103,504 entitled “Inflatable ProducePackaging,” which are hereby incorporated herein by reference in theirentireties. The present application is co-pending with U.S. patentapplication Ser. No. 14/937,869 entitled “Inflatable Produce Packaging”and Ser. No. 14/937,857 entitled “Inflatable Packaging with AdhesiveSeals”, which are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

The disclosure herein is directed to shipping containers, particularlyflexible shipping containers in agriculture.

BACKGROUND

The agriculture industry encounters regular challenges related topreserving and shipping produce prone to spoilage. Typically, produce isshipped in thin film vented PE plastic bags, corrugated containers ortrays, mesh bags or vented clamshells. When most produce, such as fruit,is shipped it can be abused in transit. This transportation abuse canaccelerate the ripening of fruit or damage the fruit, which also leadsto accelerated ripening, browning and/or bruising of the surroundingfruit. This bruising is a result of oxidation of compounds within thefruit. To limit this damage, chemical barriers are sometimes employed.One example of a chemical barrier is citric acid, which is highlyreactive to oxygen and thus reduces the oxidation of the produce itself.In addition to oxidation, damage to produce exposes the nutrients withinthe produce cells. This exposure leads to the colonization of microbessuch as E. coli and salmonella, as well as molds, fungi, and yeasts. Toreduce this colonization, produce is sometimes dehydrated slightly. Itis believed that the dehydration improves the threshold at which theproduct bruises. In some cases, produce is refrigerated to a temperatureof 32 degrees Fahrenheit to slow the ripening process or extend theshelf life during storage or transportation.

Frequent causes of produce bruising include impact between closelypacked pieces of produce and between produce and shipping containers.Larger and more massive produce can also be damaged due to the weight ofone piece of produce on another. Visco-elastic properties of someproduce can worsen the damage. Damage also has a tendency to releasecertain gases, such as ethylene, which causes some produce to increasethe rate or ripening. For example, climacteric fruits continue ripeningafter picking and thus are susceptible to accelerated ripening byethylene. Leaves, such as lettuce, are also susceptible to this ripeningprocess. It is believed that ethylene affects the genes that makeenzymes. The enzymes then catalyze reactions to alter thecharacteristics of the produce. The action of the enzymes causes theripening responses. Chlorophyll is broken down and sometimes newpigments are made so that the fruit skin changes color from green tored, yellow, or blue. Acids are broken down so that the fruit changesfrom sour to neutral. The degradation of starch by amylase producessugar. This reduces the mealy (floury) quality and increases juiciness.The breakdown of pectin, thanks to pectinase between the fruit cells,unglues them so they can slip past each other. That results in a softerfruit. Enzymes also break down large organic molecules into smaller onesthat can be volatile (evaporate into the air) and that we can detect asan aroma. Producing the ethylene also causes more ethylene to beproduced. During the shipping process the ripening and spoiling of fruitis generally considered to be negative. For example in grapes there isnot only the bruising but once the grape breaks from the stem or twistson the stem the open wound begins to oxidize and start to decay becausethe flesh is exposed to mold spores that are in the atmosphere. By addedprotection during shipping produce shelf life can be extended up to 60days. It's not necessarily how fast it will accelerate but the fact thatthere are berries that are breaking down the buyer won't be interestedin buying the product making it worthless.

In order to reduce ripening and spoiling, numerous solutions have beenoffered. Some of these solutions include partial dehydration, aircirculation around the fruit, open storage systems (e.g. open box),chemical prevention (e.g. citric acid), modifying equipment and handlingprocedure, or pre-conditioning fruit (hydration/temp); cold temperaturestorage; charcoal scrubbing of the produce atmosphere to absorb ethyleneuse of carbon dioxide and nitrogen as ripening inhibitors; physicalseparation with cardboard (or similar) dividers; and other process.These processes tend to be costly, cumbersome, or undesirable to thequality of the produce. As such, improved systems and methods may bedesirable in the industry.

SUMMARY

In accordance with various embodiments, an inflatable packaging elementis disclosed herein. The inflatable packaging element includes a firstfilm ply and second film ply overlayed on the first ply, and a sealpattern. The seal pattern has a plurality of seals sealing the first andsecond plies to each other to define an inflation chamber between thefirst and second plies. The inflation chamber is inflatable with andconfigured to contain a fluid. An aperture extends through at least oneof the first or second ply, and the seal pattern separates opposite sideof the aperture from the inflation chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a sheet of two flexible structures, according to anembodiment;

FIGS. 2A-B show one of the flexible structure of FIG. 1 being folded;

FIG. 2C shows a cross section of the flexible structure taken along theline 2C-2C in FIG. 2B;

FIGS. 3A-B show detailed views of seal portions, according to anembodiment;

FIGS. 3C-D show views a flexible structure with intermediate sealportions, according to an embodiment;

FIGS. 3E-F show views of intermediate seal portions and apertures thatare under tensile stress and shear stress

FIG. 4 shows a flexible structure of FIG. 1 that is inflated andpackaged to contain produce;

FIG. 5A-B show flexible structures that are inflated and packaged tocontain produce;

FIG. 6A-B show flexible structures that are inflated and packaged tocontain produce, and stored in crates;

FIG. 7 shows an example inflatable packaging sealing device for use insealing the flexible structures;

FIG. 8 shows a section of the flexible structure showing a cross sectionthrough the transverse seals and inflation chambers in accordance withvarious embodiments;

FIG. 9 shows film sheets that are embossed or otherwise formed to createa structural/thermal shape in accordance with various embodiments;

FIGS. 10A-B show packaging structures in accordance with variousembodiments; and

FIG. 11 show packaging structures in accordance with variousembodiments.

DETAILED DESCRIPTION

The present disclosure is related to protective packaging and systemsand methods for converting uninflated material into inflated cushionsthat may be used as cushioning or protection for packaging and shippinggoods, particularly produce or other agricultural products. Illustrativeembodiments will now be described to provide an overall understanding ofthe disclosure. Those of ordinary skill in the art will understand thatthe disclosed embodiments can be adapted and modified to providealternative embodiments for other applications, and those otheradditions and modifications can be made to the disclosure withoutdeparting from the scope of the present disclosure. For example,features of the illustrative embodiments can be combined, separated,interchanged, and/or rearranged to generate other embodiments. Suchmodifications and variations are intended to be included within thescope of the present disclosure. Similarly, the subject matter discussedherein may also be incorporated into the various system disclosed in theincorporated references. Embodiments are not meant to stand alone, butmay be combined with other embodiments from other referencedapplications or various other embodiments disclosed herein.

FIG. 1 is a schematic illustration of a flexible structure 100 inaccordance with various embodiments. The flexible structure may beformed in any of a variety of manners. For example, a plurality ofinterconnected flexible structures (e.g. 100 a, 100 b) may form acontinuous sheet.

The continuous sheet may be separated by perforations or other regionsof weakness to facilitate separating individual protective packagingunits 100 a, 100 b from each other. Lines of weakness 149 may extendtransversely to separate units that are disposed in serieslongitudinally with respect to each other. When separated, the brokenlines of weakness define longitudinal ends of the units 100 a, 100 b.These lines of weakness may be formed as perforations or similarstructures that allow a user to easily separate units by tearing theunits apart with his or her hands. As used herein, perforations may besmall ticks in the material that cause a tear to be directed to the nexttick in the material. This tick-to-tick tear may then propagate alongthe length of the perforation allowing for simple separation. The linesof weakness and specifically perforations can be distinguished fromapertures discussed herein, as the lines of weakness are directed tostructures that cause a continued propagation of a separable feature,whereas the apertures do not do so unless otherwise specifically noted.

FIG. 1 shows an embodiment of separate flexible structures (e.g. 100 aor 100 b) that can each form a container 50, as illustrated in FIG. 2B.FIG. 2A shows an example of forming a flexible structure 100 a, 100 binto a container 50, according to an embodiment. The container may beoperable to surround, hold, separate, and/or protect contents storedwithin the container. Alternatively, the flexible structure 100 may beutilized in the flat form illustrated in FIG. 1. In this form theflexible structure 100 may be utilized as a divider. The divider may bepositioned between layers of goods and thereby separate differentquantities of the goods. For example, the divider may be laid in a boxwith a layer of produce on top. Another divider may be laid on top ofthe first layer with more produce on top and so-on. In this way, onelayer of produce is divided from another layer of produce protecting thevarious layers from one-another and outside conditions. Whether theflexible layer is formed into container 50, used in its flat form, orused in another form, each of the various features discussed herein maybe applicable.

In accordance with various embodiments, the flexible structure 100 mayinclude multiple plies 105, 107 of film. The first film ply 105 has afirst longitudinal edge 102 and a second longitudinal edge 104, and asecond film ply 107 has a first longitudinal edge 106 and a secondlongitudinal edge 108. The second film ply 107 may be aligned to beoverlapping and generally coextensive with the first film ply 105, i.e.,at least respective first longitudinal edges 102,106 are aligned witheach other and/or second longitudinal edges 104,108 are aligned witheach other. In some embodiments, the plies 105,107 are partiallyoverlapping with inflatable areas in the region of overlap. The plies105,107 may be joined to define a first longitudinal edge 110 and asecond longitudinal edge 112 of the film 100. The first and second plies105,107 can be formed from a single sheet of web material, a flattenedtube of web material with one edge slit, or two sheets of web material.For example, the first and second plies 105,107 can include a singlesheet of web material that is folded to define the joined second edges104,108 (e.g., “c-fold film”). As another example, the first and secondplies 105,107 can include a tube of web material (e.g., a flatten tube)that is slit along the aligned first longitudinal edges 102,106. Inembodiments, the first and second plies 105,107 include two independentsheets of web material joined, sealed, or otherwise attached togetheralong the aligned second edges 104, 108.

In accordance with various embodiments, the structure 100 may beflexible. For example, structure 100 may be sufficiently flexible sothat it easily bends under its own weight. The structure 100 may besufficiently flexible so that a user can bend it into different shapeswithout permanently distorting, cracking, or breaking it. A thermoformplastic package is not a flexible material but more a semi-rigidmaterial that does not absorb impacts from shock and vibration.

The disclosed film ply 105,107 may comprise a monolayer or multilayerfilm. The one or more layers may include a polymer. In cases in whichthe film ply 105,107 comprises a multilayer film, the multiple layerscan include polymers of differing compositions. In some embodiments, thedisclosed layers may be selected from ethylene, amide, or vinylpolymers, copolymers, and combinations thereof. The disclosed polymerscan be polar or non-polar. The disclosed ethylene polymers may besubstantially non-polar forms of polyethylene. In many cases theethylene polymer may be a polyolefin made from copolymerization ofethylene and another olefin monomer, for example an alpha-olefin. Theethylene polymer may be selected from low, medium, or high densitypolyethylene, or a combination thereof. In some cases, the density ofvarious polyethylenes varies, but in many cases the density of lowdensity polyethylene may be, for example, from about 0.905 or lower toabout 0.930 g/cm3, the density of medium density polyethylene may be,for example, from about 0.930 to about 0.940 g/cm3, and high densitypolyethylene may be, for example, about 0.940 to about 0.965 g/cm3 orgreater. The ethylene polymer may be selected from linear low densitypolyethylene (LLDPE), metallocene linear low density polyethylene(mLLDPE), high density polyethylene (HDPE), medium density polyethylene(MDPE), and low density polyethylene (LDPE).

In some embodiments, the polar polymer may be a non-polar polyethylenewhich may be modified to impart a polar characteristic. In otherembodiments, the polar polymer is an ionomer (e.g. copolymers ofethylene and meth acrylic acid, E/MAA), a high vinyl acetate content EVAcopolymer, or other polymer with polar characteristics. In someembodiments, the modified polyethylene may be anhydride modifiedpolyethylene. In some embodiments, the maleic anhydride is grafted ontothe olefin polymer or copolymer. Modified polyethylene polymers mayreact rapidly upon coextruding with polyamide and other ethylenecontaining polymers (e.g., EVOH). In some cases, a layer or sublayercomprising the modified polyethylene may form covalent bonds, hydrogenbonds and/or, dipole-dipole interactions with other layers or sublayers,for example sublayers or layers comprising a barrier layer. In manyembodiments, modification of a polyethylene polymer may increase thenumber of atoms on the polyethylene that are available for bonding. Forexample, modification of polyethylene with maleic anhydride adds acetylgroups to the polyethylene, which may then bond with polar groups of thebarrier layer, for example, hydrogen atoms on a nylon backbone. Modifiedpolyethylene may also form bonds with other groups on a nylon backboneas well as polar groups of other barrier layers, for example, alcoholgroups on EVOH. In some embodiments, a modified polyethylene may formchain entanglements and/or van der Waals interactions with an unmodifiedpolyethylene.

Mixtures of ethylene and other molecules may also be used. For example,ethylene vinyl alcohol (EVOH) is a copolymer of ethylene and vinylalcohol. EVOH has a polar character and can aid in creating a gasbarrier. EVOH may be prepared by polymerization of ethylene and vinylacetate to give the ethylene vinyl acetate (EVA) copolymer followed byhydrolysis. EVOH can be obtained by saponification of an ethylene-vinylacetate copolymer. The ethylene-vinyl acetate copolymer can be producedby a known polymerization, such as solution polymerization, suspensionpolymerization, emulsion polymerization and the like, and saponificationof ethylene-vinyl acetate copolymer can be also carried out by a knownmethod. Typically, EVA resins are produced via high pressure autoclaveand tubular processes.

Polyamide is a high molecular weight polymer having amide linkages alongthe molecular chain structure. Polyamide is a polar polymer. Nylonpolyamides, which are synthetic polyamides, have favorable physicalproperties of high strength, stiffness, abrasion and chemicalresistance, and low permeability to gas, for example oxygen.

Other materials and constructions can be used. The disclosed flexiblestructure 100 can be rolled on a hollow tube, a solid core, or folded ina fan-folded box, or in another desired form for storage and shipment.

In accordance with various embodiments, the plies, walls, structures,etc. discussed herein may be sealed together to form the describedstructures with any process such as adhesively bonding, friction,welding, fusion, heat sealing, laser sealing, and ultrasonic welding.For example, the plies 105, 107 may be sealed together forming aninterior inflation chamber according to any known method. Furthermorethe flexible structure 100 already formed of plies 105, 107 may besealed to itself or another flexible structure 100 in order to formother structures such as for example container 50. For example, theplies or structure may be heat-sealed together or adhesively sealedtogether. An adhesive that is operable to seal the inflation chamberssufficiently to contain gas under shipping pressures may be suitable.These pressures may be caused by stacking the flexible structure 100under multiple layers of the shipped product. In some embodiments, theadhesive may be cured by exposing the adhesive to an electromagneticradiation. The adhesive may be sensitive to electromagnetic radiationsin specific areas of the electromagnetic radiation spectrum. Forexample, the adhesive may be an ultraviolet light (UV) curable adhesive.For example, heat sealing the adhesive may be applied to one or both thefilm plies 105, 107, the plies may then be laid over top of one anotherand then sealed together by applying an ultraviolet light seal. This andsimilar adhesives and methods are described in more detail in U.S. Pat.No. 8,404,071 which is hereby incorporated by reference in its entirety.The adhesive may also be a pressure sensitive or any other adhesive. Asdiscussed herein any of the seals may be made by just heat sealing, justadhesive sealing, both types of sealing, or any other type of sealing.The adhesive may be a UV curable laminating adhesive that may be used inconnection with some implementations of wet lamination. For example, theadhesive may be a UV curable, flexo type low-odor laminating adhesivefor film to film UV wet laminating applications. The adhesive can have aBrookfield Viscosity between about 700-1000 cps at 77 degreesFahrenheit. The adhesive can have a density equal to or about equal to8.6 pounds per gallon. The adhesive can have a low odor and/or a clearliquid appearance. The adhesive can have a solids content of 100%. Theadhesive can have a cure speed between about 150-220 FT/MIN with 1×300watt/in lamps. The adhesive can have a coverage equal to or about equalto 5300 FT/GAL at 0.3 mil thickness. The adhesive can have a cureabsorbance irradiance equal to or about equal to 1.3 Wcm². Theseadhesives cure well at fast speeds to provide a durable high qualitybond with specific films, such as treated LLDPE, LDPE, and metallocenecatalyzed LLDPE, and polypropylene. These adhesives have strong adhesionto both films and some papers. They are also cationic based and will notcure well in-line over aqueous or solvent amine containing inks. In someembodiments, the adhesive can have a coating thickness of approximately0.2 to 0.5 mil. A typical anilox in the 150-200 Q range can provide theappropriate coat weight. Best results may be achieved on smooth filmsand some papers. Excellent results have been obtained with polyethyleneand polypropylene films. Film surface treatment to 40-45 dynes/cm can beused to improve adhesion with low surface energy films.

In accordance with various embodiments, plies 105, 107 may be sealedtogether with seals 118. The seals 118 may be sufficiently continuous tohold a gas injected into the flexible structure 100. In this manner,each of the flexible structures (e.g. 100 a, 100 b) may be inflated toform a cushion or pillow. The cushion or pillow may take the form of astructured container 50 (see e.g. FIGS. 2A-B) or flat sheet as shown inFIG. 1. Either form may be utilized to separate a first produce quantityfrom a second produce quantity. For example, as a flat sheet an inflatedflexible structure may be placed between layers of produce. As astructured container 50, produce may be protected by placing producewithin the inflated structure.

As shown in FIG. 1, the web 100 can include a series of transverse seals118 disposed along the longitudinal extent of the web 100. Eachtransverse seal 118 extends from the longitudinal seal 112 towards alongitudinal inflation region, which may be, for example, an inflationchannel 114 that has a substantially or entirely closed periphery aboutits longitudinal axis, except for where it directs gas between the plies105, 107 of film, to receive a longitudinal inflation nozzle therein.The transverse seals 118 may be straight as shown or may be curved,zig-zag or form any geometry's or shapes suitable to the application.Alternatively, the inflation region can be provided by an open lateraledge, such as with flaps that are held over a transverse nozzle to blowgas between the film plies. In the embodiment shown, the inflationchannel 114 is closed on a side opposite the inflation chambers 120 byfirst longitudinal seal 110. Each transverse seal 118 has a first end122 proximate the second longitudinal seal 112 and a second end 124spaced a transverse dimension d from the first longitudinal seal 110 ofthe film 100. An inflation chamber 120 is defined within a boundaryformed by various seals operable to enclose a gas within. For examplethe inflation chamber 120 may be defined by the longitudinal seal 112 orlongitudinal seal 140 and pair of adjacent transverse seals 118. Thechamber may be closed by longitudinal seal 140. The flexible structure100 may be inflated in a flat form or after it has by formed into acontainer structure such as container 50. In one example, the flexiblestructure is formed by sealing plies 105, 107 together. The structure isthen inflated and after inflating it is formed into container 50. Inanother example, the flexible structure is formed by sealing plies 105,107 together. The structure is then formed into container 50 and sealedin this form. After forming into container 50 the structure is inflatedand the inflation is sealed.

Each transverse seal 118 embodied in FIG. 1 may extend substantiallyperpendicular to the second longitudinal seal 112. It is appreciated,however, that other arrangements of the transverse seals 118 are alsopossible. For example, in some embodiments, the transverse seals 118have undulating or zigzag patterns. The transverse seals 118 may becontinuous and/or discontinuous. The transverse seals 118 as well as thesealed longitudinal edges 110,112 can be formed from any of a variety oftechniques known to those of ordinary skill in the art, such as thosesealing techniques discussed above.

An inflation region such as a closed passageway, which can be alongitudinal inflation channel 114, can be provided. The longitudinalinflation channel 114, as shown in FIG. 1, is disposed between thesecond end 124 of the transverse seals 118 and the first longitudinaledge 110 of the film. The longitudinal inflation channel 114 may extendlongitudinally along the longitudinal side 110 and an inflation opening116 is disposed on at least one end of the longitudinal inflationchannel 114. The longitudinal inflation channel 114 has a transversewidth D. In the embodiment of FIG. 1, the transverse width D issubstantially the same distance as the transverse dimension d betweenthe longitudinal edge 110 and second ends 124. It is appreciated,however, that in other configurations other suitable transverse width Dsizes can be used. In accordance with other embodiments the longitudinalinflation channel may extend up the center of the flexible structure 100with openings extending from either side of the longitudinal inflationchannel into inflation chambers. In such an example, the longitudinalinflation channel may form the boundary between two walls of container50. Alternatively, the central longitudinal inflation channel may beformed in a single wall with each separate wall of container 50 havingits own separate longitudinal inflation channel. In various embodiments,each separate flexible structure, such as 100 a may be inflated withoutinflating other structures such as 100 b. Again this is independent ofwhether the structure is formed into a container. The structures may beinflated with a nozzle as discussed below or the structure may includeone way valves allowing for inflation. In various embodiments, theflexible structures, such as 100 a and 100 b may be continuouslyinflated. This may be done through a whole roll, stack, or otherquantities of such structure and again this is independent of whetherthe structure is formed into a container or not.

The second longitudinal edge 112 and transverse seals 118 cooperativelydefine boundaries of inflatable chambers 120. In various embodiments,the inflatable chambers 120 may further include intermediate seals 128.The intermediate seals 128 may seal the plies 105, 107 to one another atintermediate areas in the chamber 120. As shown in FIG. 1A, intermediateseals 128 may be transversely aligned across the chamber 120 or may belongitudinally aligned across the chamber 120. The intermediate sealsmay allow gasses to pass by the seals such that they do not block offthe chamber, thereby allowing the entire chamber to inflate. Theintermediate seals may provide a variety of functions. In variousembodiments, the intermediate seals 128 may create bendable lines thatallow for a more flexible web 100 that can be easily bent or folded.Such flexibility allows for the film 100 to wrap around regular andirregular shaped objects. In various embodiments, the intermediate seals128 may provide multiple openings into the chambers 120 from theinflation channel 114. See e.g. intermediate seals 128 that aretransversely directed between transverse seals along the left side ofFIG. 1, proximate the inflation channel 114. In various embodiments, theintermediate seals 128 may provide a folding line to fold the plies105,107 back over top of one another. See, e.g., intermediate seals 128that are longitudinally directed between transverse seals longitudinallyalong the center of the film 100 in FIG. 1.

In accordance with various embodiments, the transverse seals 118 mayinclude intermediate seal portion 129. Intermediate seal portion 129 mayhave a larger area with respect to the area of seal 118. Intermediateseal portion 129 may be an alternative seal configuration along thelength of transverse seals 118 operable to serve an additional functionover the transverse seal 118. For example, intermediate seal portion 129may seal a sufficient area of the plies 105, 107 to locate an aperturetherein without piercing the inflation chambers 120. Additionally oralternatively, intermediate seal portion 129 may provide bendable linesfor additional flexibility or bendable locations for modifying the shapeof the film 100.

The intermediate seal portion 129 may be a seal wherein the plies105,107 are attached to one another. The intermediate seal portion 129may be a section where narrow seals such as a continuation of seal 118define the intermediate seal portion 129. The intermediate seal portion129 may be an area where a wider solid seal is formed along seal 118(i.e. the area where the plies 105, 107 are attached may be a continuoussolid seal without an unattached area of plies 105, 107 within thecenter of the intermediate seal portion 129). This solid seal may form astiffer section of the web 100. The intermediate seal portion 129 may bean area where a seal such as partial seal 118 encloses a section ofunattached plies 105, 107. This non-solid seal configuration ofintermediate seal portion 129 (i.e. where the plies 105, 107 areunattached) may be a more flexible web 100.

In accordance with various embodiments, the seal 118 may include narrowportions (e.g. seal 118) and wide portions (e.g. seals 129.) The seal118 may branch off to form two seal branches defining the intermediateseal portion 129. This point of widening from seal 118 to seal portion129 may be at a transition 127. The transition may have a width that iswider than the seal portion 129. For example, the seal portion 129 mayhave a width of J. The transition 127 may widen from width J. Width Jmay be between 1½ times wider to 10 times wider than seal 118. Forexample, the transition 127 may be 5 times wider. The transition maythen narrow again to width K above and below the transition area. Or thetransition 127 may widen to the entire width of the transition area andthen narrow back to width J as the seal 118 continues. The transition127 may be concave as viewed from the chamber 120. This may allow thetransition to be gradual or not sharp. Although in some embodiments,sharp transitions can be used. In accordance with various embodiments,intermediate seal portion 129 may be circular, oval, triangular,trapezoidal, polygon or any other shape. As shown in FIG. 3A-B, theintermediate seal portion 129 may be a circle. The intermediate sealportion 129 may be seal between the first layer and the second layer.Alternatively, the intermediate seal portion 129 may be an unattachedportion of the first layer and the second layer bounded on all sides bya seal that does seal the first layer and the second layer, e.g. seal118 and/or transitions 127.

In accordance with various embodiments, a gradual transition may be usedto reduce stresses at the intermediate seal portion 129. The transition127 may reduce the tendency of the intermediate seal portion 129 fromseparating due to stresses placed on the film 100. In variousembodiments, the film 100 whether formed as a container (e.g. container50) or utilized as an inflatable sheet may have areas of increasedpressure. The pressure may arise from jagged items that contact the film100, bending of the film 100, or crushing the film 100 causing anincrease in pressure. Under this increase in pressure, a sharptransition may be a stress riser that can cause a tear or separation ofthe seal or film 100. An example of a sharp transition may be if theintermediate seal portion 129 and the seal 118 were positioned at 90degree angles relative to one another. In another example the transitionmay be gradual with a curve flowing from seal 118 to seal 129 throughtransition 127 with a blunt curve on the interior portion of the seal129. In some instances, there may be no interior portion of the seal129. The widened portion may be solid seal all the way across. In otherinstances the seal 129 may have an unattached interior, being bounded oneach side by seal portions 129.

In accordance with various embodiments, the interior portion of the seal129 may include an aperture 131. The aperture 131 may reduce oreliminate the stress on the seals. The aperture may allow the materialwithin the seal 129, (whether this material includes attached orunattached plies) to flex and distort thereby reducing the tendency ofthe seal to tear or separate.

In accordance with various embodiments, the apertures 131 may be locatedwithin seal portions that are independent of the transverse seals. Theseseals may be entirely surrounded by an air chamber. The seals locatedwithin panel 183 are one example. Seal portions may also be locatedbetween transverse seals along air chambers. The aperture may besurrounded by the seal. The seal may enclose a region in which the firstand second plies are unattached from one another, and the aperture maybe located in the unattached region. The seal may enclose a region inwhich the first and second plies are to one another, and the aperturemay be located in the sealed region. The aperture may extend throughboth the first and second plies. The aperture may comprise a firstaperture that extends through the first ply, and a second aperture thatextends through the second ply and that is aligned with the firstaperture. The aperture may be proximate a region of the plies thatexperiences elevated stress. The seal may be entirely contained withinthe inflation chamber. The seal may have first and second oppositesides, in which the first side of the seal is disposed within a firstinflation chamber and the second side of the seal is disposed within asecond inflation chamber. The seal may be formed by a heat-sealingtechnique. The seal may be formed using an adhesive. The aperture may bebound by a portion of the seal pattern. The aperture may be configuredto reduce stress at the seal. The aperture may be of sufficient size tovent gases from one side of the packaging element to another. Theaperture may comprise a plurality of apertures, and wherein the sealpattern surrounds each aperture of the plurality of apertures.

In accordance with various embodiments, the film 100 may have aplurality of apertures 131 interspersed throughout the film 100. Theapertures 131 may provide one or more of stress relief (as discussedabove) or venting. The apertures 131 may be through holes that extendthrough walls. Each aperture 131 may be a single hole, e.g. extendingthrough a single surface such as a single layer or two layers merged ata seal line, or each of the apertures 131 may be more than one hole. Forexample, the apertures 131 may be a first hole through a first layer 105that is generally aligned with a second hole through the second layer107. In some embodiments, the apertures may be misaligned withsufficient air between the plies to allow venting though the apertures.

The apertures may be structured such that they do not promote acontinuous tear between one another or across a significant portion ofthe flexible structure. For example, this means a tear in one apertureis unlikely to propagate into the next aperture and so on. Thisstructure may be accomplished by the apertures location relative to oneanother, the location of each aperture relative to another feature, orthe apertures shape. For example, the apertures may be located such thatthe space between apertures is operable to prevent or limit successivetearing between apertures. For example, the space between apertures maybe greater than twice the apertures width, three times the aperturewidth, or four times the width of the aperture. The obvious shape isapertures can be shaped to allow air passage and venting and designedare not designed to promote separation of the chambers or so they can bebroken apart. Also, the apertures can be designed to spread open duringinflation and can vary in width depending on the required ventilationdesired. In another example, the apertures may be circular in shape suchthat aperture shape is operable to prevent or limit successive tearingbetween apertures such that they do not form a perforation line. Inanother example, the apertures are separated from one another by sealboundaries such that the seal boundaries prevent or limit successivetearing between apertures.

In accordance with various embodiments, the apertures 131 may functionas vents allowing gasses to circulate through the film 100. For example,in embodiments in which the film 100 forms a bag or other sealedcontainer, apertures 131 may form vents. For example, the apertures 131may allow ethylene produced by organic material contained therein toescape and fresh air to enter. These apertures 131 may take the form ofany shape. They may be elongated slits as shown in FIGS. 1-2 and 3E-3F.The slits may have zero or insignificant width such as the widthproduced by a razor cut with shape end points. The slit may be anelongated hole having an apparent width. They may be polygons. They mayhave rounded ends as shown in FIG. 3A, or the aperture may be free ofsharp edges. The aperture may have blunt edges. The aperture may be an“X” or cross as shown in FIG. 3B.

In accordance with various embodiments, the intermediate seal portion129 may be configured to reinforce the aperture 131 passing throughplies 105 and 107. As discussed above, the intermediate seal portion 129may be a solid seal across its area (see e.g. FIGS. 3C-3H) orintermediate seal portion 129 may be separate seal portions outlining anunattached area (see e.g. FIGS. 3A-B). The aperture 131 may pass througha center portion of the intermediate seal portion 129. In this way, theintermediate seal portion 129 prevents or limits the aperture 131 frompiercing through either of the adjacent inflation chambers 120. Thus thefilm 100 is operable to provide venting through the apertures 131 andcushion via the adjacent inflation chambers 120.

As shown in FIGS. 3C-3D the intermediate seal portions 129 may undergoforces F causing stress on the structure 100 during inflation, shipping,handling, packing, storage, bending, folding, expanding (e.g. beingloaded or over loaded as a container) or other conditions the productfaces. These forces may have a tendency to separate the permanent ornon-permanent seals that hold the first layer and second layer offlexible structure 100 together. These forces may also have a tendencyto cause tears in the inflation chambers at the various seals. Theapertures may relieve stress from these longitudinal forces. Theseforces F may distort the flexible structure around the apertures,allowing the structure to shear, compress, or elongate in tension. Theapertures may allow for localized increased distortion in the areasrelieving these stress risers at the seals. This deformation may relievestress risers at or proximal to the various seals. These distortions mayreduce the likelihood of seal or wall failure. This may prevent or limitany seal separation and/or tearing into the inflation chambers. Thelocal deformation may increase stresses on the apertures 131 which maybe contained by the surrounding intermediate seal portions 129. FIG. 3Eshows an intermediate seal portion and an aperture that is under tensilestress. FIG. 3F shows an intermediate seal portion and an aperture thatis under shear stress.

In accordance with various embodiments, the apertures may be any shapeincluding die cut holes. For example, the apertures may be slits. Theslits (i.e. a long cut forming the aperture wherein the width isnegligible especially compared to the length and the slit ends in sharptransitions on either side) may form stress points on either end of theslit, which may have a tendency to cause the slits to tear. Intermediateseal portion 129 may limit this tendency and prevent or limitpropagation of the tear between adjacent apertures and/or air chambers.The apertures may be circular which may include being a circle,generally round, oblong, elliptical, oval or having generally curvedboundaries and/or limited sharp transitions between sides. Circularapertures 131 may present reduced tearing stresses on the aperture, butthe intermediate seal portion 129 may still provide isolation frominflation chambers 120 and increased strength to keep the apertures 132from tearing into the inflation chambers 120 and causing them todeflate.

In accordance with various embodiments, the flexible structure 100 mayinclude an intermediate feature. The intermediate feature may be aportion of the flexible structure 100 without chambers and/or withinterrupted chambers to form a functional element on the flexiblestructure. These functional elements may include movable panels,openings, windows, flat panels, printable panels, handles, attachmentfeatures, or the like. In one example, the intermediate feature may bean access panel 183. The access panel may include a separable boundary185 that is operable to be separated from the remaining flexiblestructure 100. This separable boundary 185 may define the openingthrough the flexible structure 100 covered by the access panel 183. Theseparable boundary 185 may be any separable structure. For example, theseparable boundary 185 may be a perforated border or a mixture ofperforated boarder and resealable border. The perforated border may beoperable to be easily torn from the flexible structure 100 at theseparable boundary 185. In another example, the separable boundary 185may be a resealable edge by utilizing, for example, a zipper seal (e.g.Ziploc-style closing). In another example, the separable boundary 185may be an adhesive seal sometimes referred to as a pressure sensitiveseal. In each of these examples the access panel 183 may be opened byseparating separable boundary 185 from the rest of the flexiblestructure 100. The separable boundary may take any or form or shape. Theseparable boundary may be enclosed or open having free ends. Forexample, the separable boundary may be rectangular, circular,triangular, linear, etc. The separable boundary may allow the panel 183to be opened like a door and allow the contents to be removed from theinterior of container 50. For example, a grape could be removed.

The separable boundary 185 may be isolated from the chambers 120. Forexample, a seal 184 may be substantially parallel to or generally followthe separable boundary 185 at an offset distance. This offset may allowthe seal 184 to separate from the chambers 120. In various embodiments,the seal 184 may be contiguousagious with seal 112. In otherembodiments, the seal may be separate and internal to seal 112. Theseparable boundary 185 may be offset from the exterior of the first wallor the second wall (e.g. edges 102, 106, 104, 108 or seals 141, 142).The separable boundary 185 may start and end on portions internal tofilm 100. In this way the perforation does not tear out to the edge ofthe film 100 nor does the separable boundary 185 cause differentportions of the structure to separate entirely. However, other weakenedareas as discussed above may do this.

In accordance with various embodiments, a gripping portion may extendfrom the panel 183. The gripping portion may be an independent flap thatprotrudes from the surface of the flexible structure 100 at the panel183. Alternatively, the gripping portion may be defined by apre-separated portion of the separable boundary 185. Alternatively, thegripping portion may be defined by a portion of the perforation that iseasily separated. The gripping portion may be operable to receive aforce and transmit that force through the panel 183 to the separableboundary 185 such that the panel 183 is at least partially separatedfrom the flexible structure 100.

In accordance with various embodiments, the panel 183 may include ahinge section. The hinge section may be defined by at least one edge ofthe panel 183 that is continuous with the rest of the flexible structure100. For example, the at least one edge of the panel 183 does not have aseparable boundary or any separating feature.

The separable boundary 185 may extend into or divide two portions of thesame chamber. In some embodiments, the door chamber has passages so thedoor can be inflated. In some embodiments, the door has no inflationchamber but may have a flat widow for viewing or panel for printinglabels onto. In accordance with various embodiments, seals 187 a or 187b, as shown in FIG. 1. may be longitudinal seals or substantiallylongitudinal seals (e.g. may have a longitudinal component andtransverse component to the direction), which interrupt one or morechambers 120 d or extend one or more chambers 120 n, 120 p beyond aninterruption. The interruption may prevent the one or more chambers 120d from extending the transverse width of the flexible structure 100. Theextension may allow a new chamber 120 n, 120 p to pick up after thefirst chamber 120 d was interrupted, thereby extending an inflatedcushion the remaining transverse distance across the flexible material.A small gap 187 c may reside between the interrupted chamber and thecontinued chamber. In this way, some chambers 120 may extend thetransverse width of the flexible structure from end 124 to end 122. Somechambers 120 n, 120 p may only extend from or to seals 187 a or somechambers 120 d may only extend to 187 b.

In accordance with various embodiments, seal 187 b may transverselyterminate the chamber 120 d at an intermittent seal 128. The seal 187may intersect with a transverse seal 118 c. Intermittent seal 128 may bea folding feature between separate walls of container 50. Theintermittent seal 128 may be discontinuous up to seal 187 b which may becontinuous. Thus intermittent seal 128 may allow the chambers 120 toinflate on both transverse sides of intermittent seal 128, whereas seal187 b may prevent or limit chambers 120 d from extending beyond the seal187 b. Intermittent seal 128 and seal 187 may be positioned along anytransverse position of flexible structure 100. For example, they may bepositioned along a centerline such that the halves of the flexiblestructure 100 can be folded back over itself. In another example, theymay be positioned a quarter of the way along the transverse distanceallowing the flexible structure to have two folds to form container 50.

In accordance with various embodiments, a seal 187 a may be alongitudinal seal that also intersects with transverse seal 118 c. Invarious embodiments, transverse seal 118 c may become discontinuousbeyond the intersection of seal 187 a. Beyond the intersection of seal187 a and 118 c only wide portions 131 of seal 118 c may be present.This discontinuous structure of transverse seal 118 c may providechannels 119 to extend between chamber 120 and chambers 120 n, 120 p.Similar channels may extend between successive chambers 120 n, 120 p ina longitudinal direction. Seal 187 a may be a longitudinal seal definingchambers 120 n between panel 183 and intermittent seal 128. In thisembodiment, a second seal may terminate chambers 120 n. Or, seal 187 amay be a seal defining an edge of panel 183 proximal to intermittentseal 128. In either embodiment, seal 187 a may be continuous with seal184 defining just the panel or the panel with the chambers 120 n. In oneembodiment, panel 183 may extend the whole width of one wall ofcontainer 50. In other embodiments, panel 183 may only extend a portionof the transverse distance across one wall of container 50 bounded onone or more sides by air chambers (e.g. chambers 120 n). In the variousembodiments, the channels 119 may allow chambers 120 p within panel 183to inflate. In this embodiment, the interior of the panel is in fluidcommunication with the inflation region, thereby providing a panel withan inflation region and the resulting protective functions.

By forming a break the chambers 120 d and/or 120 n with the intermediateseals 187 a and b and/or other seals, the process of tearing the panel183 off the opening at the perforation 185 does not deflate the adjacentinflated chambers 120, 120 n or 120 p.

As illustrated by these example embodiments, the flexible structure mayinclude any variety of intermediate features, with the panel 183 beingone example. Channels 119 and intermediate seals (e.g. 187 a, b) mayallow channels 120 to stop and continue on either side of theintermediate features. The channels 119 may also provide inflation intothe intermediate feature if the intermediate feature is not bounded onall sides like panel 183. Another example of the intermediate feature isillustrated in FIGS. 10-12 as an uninflated flat surface 509. This flatsurface 509 may be incorporated in any of the embodiments contemplatedherein. For example, it may replace panel 183 by removing chambers 120 pfrom the panel and forming the transverse seal below the panel as acontinuous panel (e.g. 118 c). In various embodiments, chamberboundaries may be formed around an enlarged uninflated portion. Thisun-inflated portion may be sufficiently large to form a viewing windowor provide product information. This un-inflated portion may be greaterthan ½ inch by 2 inches, for example. In various examples, thisun-inflated portion may be larger than other interruptions betweenchambers, such as the widened seal portions discussed above. However,the un-inflated portion may also be a seal between layers sufficientlylarge to serve a greater purpose than merely sealing. In this way theflat surface 509 would not be inflatable but may receive printing,labels, or other indicative information. The flat surface 509 may alsobe or alternatively be transparent, providing a window through theflexible film 100. This information presentation surface or window maybe applicable to the flexible film 100 in its flat state as a divider orin a formed state such as the containers discussed herein.

In accordance with various embodiments, the flexible structure 100 mayinclude a handle 150. The handle may be any area or opening operable toplace a user's fingers through to hold the product. The handle may beprovided by forming a weakened area or cutting an aperture through theflexible structure 100 in either a flat form or a structured form suchas container 50. Handle 150 may be located proximal a transverse edge149 of flexible structure 100. Handle 150 may be defined by one or moresealed portions of the flexible structure 100 operable to be utilized asa handle. In one example, an exterior handle seal 151 may be positionedproximal to a transverse edge/seal 149 or in another desired location.In various embodiments, separate exterior handle seals 151 may bepositioned generally symmetrically about longitudinal centerline 128 orin another useful configuration. The handle 150 may include an interiorhandle seal 153 located within the one or more handle seals 151. A spacebetween exterior handle seal 151 and the interior handle seal 153 maydefine a separable portion of the handle. In various embodiments, theseparable portion may be a line of weakness 155, which may extend atleast partially around the space between exterior handle seal 151 andthe interior handle seal 153. The lines of weakness 155 may be broken,revealing an aperture through the film. When the symmetric handles 150are overlapped, the apertures may align, creating a portion of container50 that can be gripped as a handle.

As alluded to above, the flexible structure may be used in a flatconfiguration or it may be formed into container 50 (see e.g., FIG. 4).Container 50 may be formed from two separate sheets of flexiblestructure 100 sealed together or container 50 may be formed from asingle sheet of flexible structure 100 that is folded and sealedtogether as illustrated in FIGS. 2A and 2B. The container 50 may also bestructured from any number of sheets of flexible structure 100 formingmore than two walls as the various application dictates. FIG. 2Aillustrates a schematic of the flexible structure being folded inaccordance with various embodiments. As discussed above, the flexiblestructure 100 may be folded along intermittent seal 128. Thisintermittent seal may be anywhere in any number, such that flexiblestructure 100 may be folded with any number of folds. In variousembodiments, the flexible structure 100 may be folded along thecenterline as illustrated in the example of FIG. 2A. Folding theflexible structure 100 in this way may allow the edges 102,106 and104,108 to align. With the flexible structure 100 folded, the first walland the second wall may be sealed along a plurality of seals. Forexample, as illustrated in FIG. 2B, these seals may include one or moreof top seal 145, external longitudinal seal 142, internal longitudinalseal 141, and bottom seal 159. A second transverse seal similar to theseal 145 may additionally be formed along the transverse edge 149. Thesecond transfer seal may be an alternative seal to seal 145. In someembodiments, the handles may also be sealed together at 150. These sealsmay be made after produce, or other content, has been placed in thecontainer 50. The seals may be made with mechanical attachment (e.g. zipstyle), with heat, with an adhesive, or any other way known in the art.The first wall and the second wall of the container 50 may be sealedalong adhesive seals shown in FIG. 2A. For example, seals on the firstwall 50 a may include one or more of seals 141 a, 142 a, 159 a, 150 aand 145 a. Seals on the second wall 50 b may include one or more ofseals 141 b, 142 b, 159 b, 150 b and 145 b. The seals may form theboundary around an unattached portion defining the interior 147 of thecontainer 50. The interior 147 may receive the produce or other content.Seals 141 a, 142 a, 159 a, 150 a 145 a, 141 b, 142 b, 159 b, 150 b and145 b are operable to connect walls which are made up of multiple pliesof film. Thus these seals do not necessarily extend between plies 105,107 but may do so. These seals may extend merely from ply 105 to ply 105or ply 107 to ply 107, thus forming walls of the containers. It shouldbe noted that in situation in which an adhesive is used, it may beplaced on each of the “a” and “b” locations, such as 141 a and 141 b forexample. The adhesive may be any kind of adhesive, such as, but notlimited to, an ultraviolet (UV) curable adhesive. However it may beplaced on only one of these locations such as 141 a and when thestructure 100 is folded 141 a may align with 141 b such that he seal isformed in both locations. This may apply to 142 a,b 159 a,b and 145 a,bas well.

FIG. 4 illustrates packaged produce contained within an inflatedflexible structure in accordance with various embodiments. Asillustrated, quantities of the packaged produce 300 may be separatedfrom one another by the flexible structure shown here as container 50.The chambers 120 provide protection to the produce 300. The apertures131 provide venting to the produce 300. Tab 187 provides access toproduce 300 as discussed above. Handle 150 allows carrying of produce300.

In accordance with various embodiments, any produce may be packaged withthe flexible structures 100. However, packaging certain produce with theflexible structures 100 may significantly extend the life of theproduce. For example, produce with visco-elastic properties can beprotected by the flexible structure 100, reducing damage that frequentlyoccurs to the produce due to its structural properties. As damage alsohas a tendency to release certain gases such as ethylene, the venting inthe flexible structure 100 may further benefit the produce bycirculating the gasses away. This may be desirable in climacteric fruitswhich continue ripening after picking and thus are susceptible toaccelerated ripening by ethylene. Leaves, such as lettuce, are alsosusceptible to this ripening process. By both reducing thebruising/damage to the produce and venting away ethylene, effects to thegenes that make enzymes within the produce is reduced. The action of theenzymes to cause the ripening response is thereby reduced. Produce thatmay fall in these categories may include grapes, apples, lettuce,potatoes, onions, bananas, and others known in the art. Each container50 may contain a ½ lb. of fruit to 5 lbs. of fruit. For example, eachcontainer may contain about ½ lb to 2 lbs of fruit.

FIGS. 5A-B illustrate group packaged produce contained within aplurality of inflated flexible structures in accordance with variousembodiments. As illustrated, the flexible structure 100 may be formedinto containers 50 a,b,c. These containers may be packaged together intoa single bundle. FIG. 5A illustrates two containers 50 a,b combinedtogether with a single structural handle 51 adding support to thehandle. The structural handle 51 may be cardboard, plastic or any otherknown shipping material that may hold multiple containers together andadd support to the handle. The structural handle 51 may also serve as alabel surface for identification and information purposes. FIG. 5Billustrates a chain of tree containers 50 a,b,c, combined together. Invarious embodiments, the flexible structures can be filled and sealedwithout separating them from one another. FIG. 1 shows two connectedflexible structures 100 a, 100 b. By filling and sealing the connectedflexible structures, a chain of connected containers 50 a,b,c may beformed. This may simplify shipping and purchasing aspects of theindustry. Alternatively, the structures may be separated thenreconnected via structural handles 51 a,b,c.

The packaged produce may then be shipped, contained, or displayed inbulk containers. FIG. 6A-B illustrates packaged produce contained withina plurality of inflated flexible structures and stored in crates inaccordance with various embodiments. With the containers 50 protectingthe produce, the produce may be able to be stacked deeper in a cratesuch as shown in FIG. 6B. In this way, produce can be shipped, containedand displayed in larger containers allowing additional efficiencies inthe industry.

FIG. 7 illustrates an example of an inflatable packaging sealing device101 for use in sealing the inflatable flexible structures. the inflationand sealing device 101 may be operated to convert a flexible structure100 of uninflated material into a series of inflated pillows or cushionsby inflating chambers 120. As shown in FIG. 7, the uninflated web 100can be a bulk quantity of supply, uninflated material. For example,uninflated flexible structure 100 may be provided in bulk form on a rollto be inflated and sealed by the device 101. For example, the bulkquantity of uninflated material may be a roll of the material 134. Theflexible structure 100 may be rolled around an inner support tube 133.

The inflation and sealing device 101 may include a bulk material support136. The bulk quantity of uninflated material may be supported by thebulk material support 136. For example, the bulk material support may bea tray operable to hold the uninflated material, which can be providedby a fixed surface or a plurality of rollers, for example. To hold aroll of material the tray may be concave around the roll or the tray mayconvex with the roll suspended over the tray. The bulk material supportmay include multiple rollers which suspend the web. The bulk materialsupport may include a single roller that accommodates the center of theroll of web material 134. The roll of the material 134 may be suspendedover the bulk material support 136, such as a spindle passing throughthe core 133 of the roll of the material 134. Typically, the roll coreis made of cardboard or other suitable materials.

In accordance with various embodiments, the nozzle may inflate web 100not only at a transverse edge but may engage an inflation channellocated at any transverse distance between the longitudinal edges; i.e.,the inflation and sealing device 101 fills a central channel withchambers on both transverse sides of the inflation channel. The web 100may roll off of material support 136 and over guide 138 in a manner thataligns such a central inflation channel 114 of the flexible structure100 with the nozzle in inflation area 142.

The inflation and sealing device 101 may be configured for continuousinflation of the web 100 as it is unraveled from the roll 134. The roll134 includes the plurality of inflation chambers 120 that are arrangedin series. To begin manufacturing of the inflated pillows from the webmaterial 100, the inflation opening 116 of the web 100 is insertedaround an inflation assembly, such as an inflation nozzle in inflationregion 142. The web 100 is advanced over the inflation nozzle with thechambers 120 extending transversely with respect to the inflation nozzleand an outlet on the inflation nozzle. The outlet, which can be disposedon a radial side and/or the upstream tip of the nozzle, for example,directs fluid from a nozzle body into the chambers 120 to inflate thechambers 120 as the web 100 advances along the material path in alongitudinal direction. The inflated web 100 is then sealed by a sealingmechanism in the sealing area 174 to form a chain of inflated pillows orcushions.

The inflation nozzle inserts fluid, such as pressured air, along a fluidpath into the uninflated web material through nozzle outlets, inflatingthe material into inflated pillows or chambers 120. The inflation nozzlecan include a nozzle inflation channel that fluidly connects a fluidsource with the nozzle outlets. It is appreciated that in otherconfigurations, the fluid can be other suitable pressured gas, foam, orliquid. The web 100 is fed over the inflation nozzle, which directs theweb to the inflation and sealing assembly 103. The web 100 is advancedor driven through the inflation and sealing device 101 by a drivemechanism, such as by a driver or sealing drum or the drive roller, in adownstream direction along a material path.

After being fed through the web feed area 164, the first and secondplies 105,107 are sealed together by the sealing assembly and exit thesealing drum. The sealing drum may include heating elements, such asthermocouples, which melt, fuse, join, bind, or unite together the twoplies 105,107, or other types of welding or sealing elements. The web100 is continuously advanced through the sealing assembly along thematerial path and past the sealing drum at a sealing area 174 to form acontinuous longitudinal seal along the web by sealing the first andsecond plies 105,107 together, and exits the sealing area. In variousembodiments, the inflation and sealing device 101 further includes acutting assembly to cut the web off the inflation nozzle when aninflation channel that receives and is closed around a longitudinalinflation nozzle is used.

In accordance with various embodiments, the inflation and sealing devicecan have more than one belt. For example, one belt may drive the variousrollers and a second belt may pinch the web against the sealing drum. Invarious embodiments, the inflation and sealing device may have no belts.For example, the sealing drum may pinch the web against a stationaryplatform and drive the web thorough the inflation and sealing device atthe same time.

In accordance with various embodiments, these components and othercomponents which may be utilized within an inflation and sealing device101 including without limitation, the nozzle, blower sealing assembly,and drive mechanisms, and their various components or related systemsmay be structured, positioned, and operated as disclosed in any of thevarious embodiments described in the incorporated references such as,for example, U.S. Pat. No. 8,061,110; U.S. Pat. No. 8,128,770; U.S.Patent Publication No. 2014/0261752; and U.S. Patent Publication No.2011/0172072 each of which is herein incorporated by reference. Each ofthe embodiments discussed herein may be incorporated and used with thevarious sealing devices of the incorporated references and/or otherinflation and sealing devices. For example, any mechanism discussedherein or in the incorporated references may be used in the inflationand sealing of flexible structure 100 as the web or film materialdescribed in the incorporated references.

As discussed above, the flexible structure may be heat sealed oradhesive sealed. Furthermore, the flexible structure may be folded intoforming the first and second walls of the container, which may be sealedtogether by heat sealing or adhesive sealing. Alternatively, the firstwall and the second wall may be formed as separate flexible structureswhich may be sealed together by heat sealing or adhesive sealing. Assuch, the mechanisms and processes above for heat sealing are notintended to limit the scope but merely provide explanation of exampleprocesses and devices for performing the task. Adhesive sealing of theflexible structure or the walls forming the container may be performedby any method known in the art.

In accordance with one embodiment, as shown in the example FIG. 8 whichillustrates a cross section through an inflated chamber, a section ofthe inflatable container 501 may include inflatable chambers 501.Inflatable chambers 501 may vary in length to support various shapes.The inflatable chambers 501 may be a length 502 which may be suitable toform any side of container such as a produce container. The length 502may increase or decrease depending on the shape. For example, length 502may be sufficiently long to wrap around the perimeter of a designedquantity of produce. An outer surface 503 may contact the produce andseparate each package from the other. An inner volume 504 of thestructure may hold the inflation gases. The gases may add rigidity tothe chamber 501, thereby doubling as a structural member. The inflatedchambers 501 may also serve as a thermal barrier to extend the produceshelf life of the product. A seal 505 may be welded together using aheated element. A series of apertures 506 may be provided through theseal 505 such that the produce may be vented of gases or the produce maybe watered down during transit and point of sale through the apertures.The apertures may be close together but have rounded ends so as to limitor prevent propagations of tears between one another.

FIG. 9 illustrates film sheets that are embossed to create a structuralshape in accordance with various embodiments. Two plies may be sealedand trap air between the two. This assembly may be used as a wall of acontainer or divider for protecting contents such as produce. Multiplesheets can be combined to form a container. Chamber ends 503 may beprovided to seal off ends of the chambers. As shown in FIG. 9, the twosheet halves may be formed separately and then heat sealed together.

In accordance with various embodiments, as shown in FIGS. 10A-B whichillustrate packaging structures formed as a container, the chambers 501may be formed as circular hoops defining an interior storage area of thecontainer. In various embodiments a flat flexible structure may be bendinto the circular shape of FIGS. 10A-B. The inflation channel 514 mayrun proximal to the handle 507. End caps 506 may be applied to containthe sides of the container. An intermediate feature 509 may be formed onone side of the container by interrupting the chambers 501. The featuremay be a flat label, a window, an access point or the like. The feature509 may be flat so as to reduce distortion of the label or transmissionof light through a window. A handle 507 may be included as a terminationpoint for the chambers 501. The chamber ends 503 may be positioned atthe base of the container. A side panel 505 may be sealed onto theflexible structures forming the chambers 503. The separate side panelmay provide the cylindrical shape to the flexible structures forming thechambers 503.

In accordance with various embodiments, as shown in FIGS. 10A-B and 11which illustrate alternatives to the packaging structures, the chamberscan be arranged to provide a variety of shipping structures. FIG. 10Billustrates chambers that are vertical or perpendicular to the handle507. The crease lines show in the side wall are formed by bringing thestructure from a flat form to the 3-dimensional form. FIG. 11illustrates chambers that are horizontal or parallel to the handle 507.

Any and all references specifically identified in the specification ofthe present application are expressly incorporated herein in theirentirety by reference thereto. The term “about,” as used herein, shouldgenerally be understood to refer to both the corresponding number and arange of numbers. Moreover, all numerical ranges herein should beunderstood to include each whole integer within the range.

The various embodiments discussed herein provide a cost-competitivesuper structure that may be able to replace corrugated cardboard. Thevarious embodiments discussed herein are able to drain water whencleaning and packaging produce and improve the end product. Furthermore,the various embodiments discussed herein improve efficiency ofmanufacture. For examples, the various embodiments discussed herein mayprovide as pre-inflated “bags on a reel” used to take off the reel forsimplicity, automation, and compaction, or the various embodimentsdiscussed herein may be provided as uninflated material on a reel readyto be inflated and sealed on site to reduce shipping bulk of thepackaging products. The various embodiments discussed herein also lendthemselves to simplified printing and/or advertising on the productpackaging. The various embodiments discussed herein provide a protectivebarrier that is able to minimize damage to the product being shipped. Asthe spoilage of produce is directly related to bruising and trapping ofcertain gasses, the various embodiments discussed herein are able toaddress both these issues and prolong the life of the produce.

What is claimed is:
 1. An inflatable packaging element, comprising: afirst film ply and second film ply overlayed on the first ply to form afirst wall; a seal pattern comprising a plurality of seals sealing thefirst and second plies to each other to define a plurality of inflationchambers between the first and second plies, each of the inflationchambers being sealed from each other and inflatable with and configuredto contain a fluid; and a second wall connected to the first wall on atleast three sides of each wall to define a bag having a bag interior;wherein the plurality of seals includes a first aperture seal thatsurrounds an aperture that extends through at least one of the first andsecond plies adjacent at least a first of the chambers, the apertureseal sealing the at least one first chamber from the aperture, and theaperture seal protruding into the first chamber such that the apertureseal extends around opposite sides of the aperture within the firstchamber.
 2. The inflatable packaging element of claim 1, wherein theaperture seal encloses a region in which the first and second plies areunattached from one another, and wherein the aperture is located in theunattached region.
 3. The inflatable packaging element of claim 1,wherein the aperture extends through both the first and second plies. 4.The inflatable packaging element of claim 3, wherein the aperturecomprises: a first aperture that extends through the first ply, and asecond aperture that extends through the second ply and that is alignedwith the first aperture.
 5. The inflatable packaging element of claim 1,wherein the aperture is proximate a region of the plies that experienceselevated stress, and the aperture is configured to reduce stress at theaperture seal.
 6. The inflatable packaging element of claim 1, whereinthe plurality of seals includes a second aperture seal that is entirelycontained within at least one of the plurality of inflation chambers. 7.The inflatable packaging element of claim 1, wherein: the aperture sealhas first and second opposite sides, the plurality of inflation chambersincludes first and second inflation chambers, and the first side of theaperture seal protrudes into the first inflation chamber and the secondside of the aperture seal protrudes into the second inflation chamber.8. The inflatable packaging element of claim 1, wherein the apertureseal is formed using an adhesive.
 9. The inflatable packaging element ofclaim 1, wherein the aperture comprises a plurality of apertures, andwherein the plurality of seals surround each aperture of the pluralityof apertures.
 10. The inflatable packaging element of claim 1, whereinthe first and second film plies form a continuous wall, and wherein thefirst wall and the second wall are formed by folding the continuous wallin a c-fold.
 11. The inflatable packaging element of claim 1, whereinthe first wall comprises an access panel, the access panel beingseparable from a remainder of the first wall to provide access to thebag interior.
 12. The inflatable packaging element of claim 1, whereinthe seal pattern defines an inflation region that is fluidly connectedto the plurality of inflation chambers to inflate the inflationchambers.
 13. The inflatable packaging element of claim 12, wherein theinflation region is a channel having an enclosed periphery.
 14. Theinflatable packaging element of claim 12, wherein the inflation regionextends longitudinally along the plies and the seal defining theinflation chamber extends generally transversely across the plies. 15.The inflatable packaging element of claim 1, wherein the aperture sealprotrudes into a second chambers.
 16. The inflatable packaging elementof claim 1, wherein the aperture seal extends around the aperturebetween the first chamber and an adjacent chamber.
 17. The inflatablepackaging element of claim 1, wherein the fourth side of each of thefirst wall and the second wall is detached from the other allowingaccess to the bag interior.
 18. An inflatable packaging element,comprising: a first film ply and second film ply overlayed on the firstply; and a seal pattern comprising a plurality of seals sealing thefirst and second plies to each other to define a plurality of inflationchambers between the first and second plies, each of the inflationchambers being inflatable with and configured to contain a fluid; and aregion of weakness extending across the film plies between some of thechambers, the region of weakness configured to propagate tearing alongthe region of weakness to facilitate separation of portions of theplies, wherein an aperture extends through at least one of the first andsecond plies, and is disposed outside the region of weakness.
 19. Theinflatable packaging element of claim 18, wherein an aperture sealextends between two adjacent chambers and around the aperture.
 20. Theinflatable packaging element of claim 18, wherein the aperture issurrounded by a seal that limits or prevents the propagation of tearingalong the plies.
 21. The inflatable packaging element of claim 18,wherein the region of weakness includes a line of perforations.
 22. Aninflatable packaging element, comprising: a first film ply and secondfilm ply overlayed on the first ply; and a seal pattern comprising aplurality of seals sealing the first and second plies to each other todefine a plurality of inflation chambers between the first and secondplies, each of the inflation chambers being inflatable with andconfigured to contain a fluid, the seals defining an elongated area thatis sealed off from and defines boundaries of the chambers on oppositesides thereof, the elongated area having a variable width, as measuredacross the elongated area between the boundaries of the chambers and theelongated area, such that the elongated area includes a wider portionand a narrower portion; wherein the wider portion of the elongated areasurrounds an aperture that extends through at least one of the first andsecond plies.
 23. The inflatable packaging element of claim 22, whereinthe aperture extends through both the first and second plies.
 24. Theinflatable packaging element of claim 22, wherein the wider portionencloses a portion of the plies sealed off from the chamber with a sealand the aperture is spaced apart from the seal such that it issurrounded by the portion of the plies.
 25. The inflatable packagingelement of claim 22, further comprising an inflation region that extendslongitudinally along the plies and is in fluid communication with thechambers to direct the fluid into the chambers, wherein the elongatedarea extends transversely with respect to the inflation region.
 26. Theinflatable packaging element of claim 25, wherein the inflation regioncomprises a longitudinal inflation channel in fluid communication withthe chambers oriented in a transverse direction.
 27. The inflatablepackaging element of claim 22, wherein the narrower portion extends fromthe wider portion.
 28. The inflatable packaging element of claim 22,wherein the elongated area has at least two wider portions separated byand contiguous with the narrower portion.